US9586737B2 - Elastomeric closure with barrier layer and method for its manufacture - Google Patents

Elastomeric closure with barrier layer and method for its manufacture Download PDF

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US9586737B2
US9586737B2 US13/500,562 US201013500562A US9586737B2 US 9586737 B2 US9586737 B2 US 9586737B2 US 201013500562 A US201013500562 A US 201013500562A US 9586737 B2 US9586737 B2 US 9586737B2
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barrier film
elastomeric closure
film
linear
cross
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US20120205374A1 (en
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Thomas Klumpen
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West Pharmaceutical Services Deutschland GmbH and Co KG
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West Pharmaceutical Services Deutschland GmbH and Co KG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D51/00—Closures not otherwise provided for
    • B65D51/002—Closures to be pierced by an extracting-device for the contents and fixed on the container by separate retaining means
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61J—CONTAINERS SPECIALLY ADAPTED FOR MEDICAL OR PHARMACEUTICAL PURPOSES; DEVICES OR METHODS SPECIALLY ADAPTED FOR BRINGING PHARMACEUTICAL PRODUCTS INTO PARTICULAR PHYSICAL OR ADMINISTERING FORMS; DEVICES FOR ADMINISTERING FOOD OR MEDICINES ORALLY; BABY COMFORTERS; DEVICES FOR RECEIVING SPITTLE
    • A61J1/00—Containers specially adapted for medical or pharmaceutical purposes
    • A61J1/14—Details; Accessories therefor
    • A61J1/1406—Septums, pierceable membranes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
    • A61M5/178—Syringes
    • A61M5/31—Details
    • A61M5/315—Pistons; Piston-rods; Guiding, blocking or restricting the movement of the rod or piston; Appliances on the rod for facilitating dosing ; Dosing mechanisms
    • A61M5/31511—Piston or piston-rod constructions, e.g. connection of piston with piston-rod
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D39/00—Closures arranged within necks or pouring openings or in discharge apertures, e.g. stoppers
    • B65D39/0052—Closures arranged within necks or pouring openings or in discharge apertures, e.g. stoppers made in more than one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D39/00—Closures arranged within necks or pouring openings or in discharge apertures, e.g. stoppers
    • B65D39/02—Disc closures
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
    • A61M5/178—Syringes
    • A61M5/31—Details
    • A61M2005/3103—Leak prevention means for distal end of syringes, i.e. syringe end for mounting a needle
    • A61M2005/3104—Caps for syringes without needle

Definitions

  • the present invention relates generally to an elastomeric closure having a barrier film layer.
  • the present invention relates to an elastomeric closure having a barrier film layered internally of the elastomeric closure.
  • Elastomeric closures are generally used as sealing devices for vials, medical vessels, instruments, syringes, etc.
  • a closure material of a medicament vessel it is generally required that the material have heat resistance, compression strain resistance, be chemically inert, and have a low permeability to gases and water vapor.
  • elastomers which have excellent sealing properties, are often used for closure materials for medicament vessels.
  • conventional elastomers while generally having low permeability, still suffer from the permeation and transmission of gases, such as water vapor and oxygen.
  • an elastomeric closure that can sufficiently seal a vessel or device and provide a barrier to the transmission of water vapor and/or oxygen and other fluids through the closure without introducing the barrier material as a secondary source of contamination for the vessel or its contents.
  • the water vapor and/or gas vapor transmission problem of elastomeric closures is solved by engendering a barrier film layer internal to the elastomeric closure, and preferably one that spans the entire width of the closure.
  • the barrier film layer not only provides a barrier to the transmission of water vapor and/or gases through the elastomeric closure, but also prevents the barrier film layer from serving as a secondary source of contaminates for the internal contents of a vessel or device used in conjunction with the elastomeric closure.
  • the present invention provides an elastomeric closure that includes a top portion, a bottom portion and a barrier film.
  • the top portion includes a bottom surface and the bottom portion includes a top surface in facing engagement with the bottom surface of the top portion.
  • the barrier film is located between the bottom surface of the top portion and the top surface of the bottom portion.
  • the present invention provides a method of manufacturing an elastomeric closure having a top portion, a bottom portion, and a barrier film located between the top portion and the bottom portion.
  • the method includes the steps plasma treating a top surface and bottom surface of the barrier film to increase its surface energy, and then layering the plasma treated barrier film on a first layer of uncured elastomer.
  • the method further includes the steps of hot pressing and vulcanizing the plasma treated barrier film and the first layer of uncured elastomer together to form the bottom portion of the elastomeric closure bonded to the plasma treated barrier film, and hot pressing and vulcanizing the bottom portion of the elastomeric closure bonded to the plasma treated barrier film to a second layer of uncured elastomer to form a top portion of the elastomeric closure bonded to the plasma treated barrier film.
  • the present invention provides a method of manufacturing an elastomeric closure having a top portion, a bottom portion, and a barrier film located between the top portion and the bottom portion.
  • the method includes the steps of forming a first bonding layer and a second bonding layer on the barrier film, and then layering the barrier film on a first layer of uncured elastomer.
  • the method further includes the steps hot pressing and vulcanizing the barrier film and the first layer of uncured elastomer together to form the bottom portion of the elastomeric closure bonded to the barrier film, and hot pressing and vulcanizing the bottom portion of the elastomeric closure bonded to the barrier film to a second layer of uncured elastomer to form a top portion of the elastomeric closure bonded to the barrier film.
  • the present invention provides a method of manufacturing an elastomeric closure having a top portion, a bottom portion, and a barrier film located between the top portion and the bottom portion.
  • the method includes the steps of mixing uncured elastomer with an adhesion promoter, and then layering the barrier film on a first layer of uncured elastomer with adhesion promoter.
  • the method further includes the steps hot pressing and vulcanizing the barrier film and the first layer of uncured elastomer with adhesion promoter together to form the bottom portion of the elastomeric closure bonded to the barrier film, and hot pressing and vulcanizing the bottom portion of the elastomeric closure bonded to the barrier film to a second layer of uncured elastomer with adhesion promoter to form a top portion of the elastomeric closure bonded to the barrier film.
  • FIG. 1 is a front-side, elevational view of an elastomeric closure in accordance with a preferred embodiment of the present invention
  • FIG. 2 is a top plan view of the elastomeric closure of FIG. 1 ;
  • FIG. 3 is an enlarged, side, cross-sectional, elevational view of the elastomeric closure of FIG. 1 ;
  • FIG. 4 is an enlarged top, rear, perspective view of a bottom portion of the elastomeric closure of FIG. 1 with a barrier film;
  • FIG. 5 is a schematic, partial, side elevational view of a barrier film applicable to the elastomeric closure of FIG. 3 ;
  • FIG. 6 is a schematic, partial, side elevational view of a barrier film having bonding layers on both its top and bottom surfaces applicable to the elastomeric closure of FIG. 3 , in accordance with another aspect of the present invention
  • FIG. 7 is a schematic, partial, side elevational view of a barrier film applicable to the elastomeric closure of FIG. 3 that is plasma treated;
  • FIG. 8 is an enlarged, schematic, partial, side, cross-sectional, elevational view of the barrier film of FIG. 7 layered within the elastomeric closure of FIG. 3 ;
  • FIG. 9 is an enlarged, schematic, partial, side, cross-sectional, elevational view of a bottom portion of the elastomeric closure of FIG. 3 in a bottom cavity mold layered with a barrier film applicable to the present invention
  • FIG. 10 is an enlarged, schematic, partial, side, cross-sectional, elevational view of a bottom portion of the elastomeric closure of FIG. 9 and another layer of elastomer within a top mold cavity for forming a top portion of the elastomeric closure of FIG. 3 ;
  • FIG. 11 is a schematic, partial, side elevational view of a barrier film applicable to the elastomeric closure of FIG. 3 that is treated with plasma enhanced chemical vapor deposition;
  • FIG. 12 is an enlarged, schematic, partial, side, cross-sectional, elevational view of a bottom portion of the elastomeric closure of FIG. 3 in a bottom cavity mold layered with a barrier film having bonding layers;
  • FIG. 13 is an enlarged, schematic, partial, side, cross-sectional, elevational view of a bottom portion of the elastomeric closure of FIG. 12 and another layer of elastomer within a top mold cavity for forming a top portion of the elastomeric closure of FIG. 3 ;
  • FIG. 14 is a schematic flow chart of a method of manufacturing the elastomeric closure of FIG. 1 in accordance with another aspect of the present invention.
  • FIG. 15 is a partial, cross-sectional, elevational view of a syringe with a plunger and tip cap in accordance with another preferred embodiment of the present invention.
  • FIG. 16 is a partial, cross-sectional, elevational view of a sealing disk in accordance with yet another preferred embodiment of the present invention.
  • the present invention provides for an elastomeric closure 10 , as shown in FIGS. 1-4 .
  • the elastomeric closure 10 includes a top portion 12 , a bottom portion 14 and a barrier film 16 located between the top portion 12 and the bottom portion 14 .
  • the top portion 12 and bottom portion 14 in combination, substantially form the elastomeric closure 10 for a device or vessel, such as a medicament vessel, vial or syringe plunger.
  • the configuration of the elastomeric closure 10 can be of any conventional closure, such as a NovaPureTM closure stopper or Westar® RU stopper by West Pharmaceutical Services, Inc.
  • a syringe piston 400 a syringe tip cap 500 , a sealing disk 600 ( FIGS. 10 and 11 ) or any other elastomeric closure for conventional vials, evacuated blood collection tubes and the like.
  • the present invention can be applied to any elastomeric closure configuration for any type of vessel system or device that requires a vapor and fluid tight seal to be maintained.
  • the elastomeric closure 10 includes a length “L”, a width “W” and a height “H”.
  • the width W is the overall width of the elastomeric closure stopper 10 .
  • a width W′ is the width of the elastomeric closure along the bottom portion 14 (or annular leg portion).
  • the top portion 12 can be any upper section of the elastomeric closure sectioned off about a generally horizontal plane, whereas the bottom portion 14 is the remainder of the elastomeric closure, or vice versa. As best shown in FIG. 3 , the top portion 12 is defined by or separated from the bottom portion 14 by the barrier film 16 .
  • the elastomeric closure 10 includes a top portion 12 having a bottom surface 13 and a bottom portion 14 having a top surface 15 in facing engagement with the bottom surface 13 of the top portion 12 , as shown, for example, in FIG. 3 . Additionally, the barrier film 16 is located between the bottom surface 13 of the top portion 12 and the top surface 15 of the bottom portion 14 .
  • the elastomeric material used for the elastomeric closure can be, for example, a synthetic or natural rubber, such as butyl rubber, isoprene rubber, butadiene rubber, halogenated butyl rubber (e.g., bromobutyl rubber), ethylene propylene terpolymer, silicone rubber, combinations thereof and the like.
  • a synthetic or natural rubber such as butyl rubber, isoprene rubber, butadiene rubber, halogenated butyl rubber (e.g., bromobutyl rubber), ethylene propylene terpolymer, silicone rubber, combinations thereof and the like.
  • the bottom portion 14 is configured with an upper section 17 (i.e., a proximal end of the bottom portion 14 ) that includes a center portion 18 concentric about the lower sides 22 of the elastomeric closure 10 and an outer flange or sloped region 20 that circumscribes the center portion 18 .
  • the center portion 18 has a diameter preferably at least 50% of the overall diameter of the bottom portion 14 and extends proud of the outer flange/sloped region 20 . That is, the center portion 18 is an upper region 18 of the bottom portion 14 that is preferably frustum shaped.
  • the outer flange/sloped region 20 can be configured as a generally horizontal surface or an angled surface 20 ′ that slopes outwardly and downwardly, as shown in FIG.
  • the angled surface 20 ′ slopes from about 2 to 25 degrees and more preferably from about 5 to 15 degrees.
  • the center portion 18 can also be configured with a rounded edge 24 leading from an upper surface 26 of the center portion 18 to the outer flange/sloped region 20 .
  • the top portion 12 includes a lower section or a lower region 28 that includes a bottom surface geometry that generally compliments and mates with the configuration of the upper section 17 and upper region 18 of the bottom portion 14 .
  • the lower section 28 includes a recess 30 concentric about the upper sides 32 of the elastomeric closure stopper 10 .
  • the recess 30 is configured with a depth and a diameter that generally compliments and mates with the frustum shaped center portion 18 of the bottom portion 14 .
  • the lower section 28 of the top portion 12 is configured as a female end that compliments and mates with the upper section 17 of the bottom portion 14 configured as a male end.
  • the male and female ends of the top and bottom portions 12 , 14 advantageously provide for improved structural strength and manufacturability when the top portion 12 and bottom portion 14 are secured and sealed together, as further described below.
  • the bottom portion 14 can be configured as a female end and the top portion 12 configured as a male end.
  • the lower section 28 and upper section 17 can be configured with any male and female ends, interlocking ends, or engaging ends to provide a more advantageous interlock between the top and bottom portions 12 , 14 .
  • the upper region 18 can be configured as a cylindrical, pyramidal or annular shape, while the lower region 28 of the top portion 12 is complimentarily shaped.
  • the barrier film 16 is configured to be located between the top portion 12 and bottom portion 14 of the elastomeric closure 10 .
  • the barrier film 16 extends or spans completely or almost completely (i.e., partially) across the top surface 15 of the bottom portion 14 ( FIG. 4 ) and/or across the bottom surface 13 of the top portion 12 ( FIG. 3 ). That is, the barrier film 16 spans completely or substantially completely across the entire width and length that divides the top and bottom portions 12 , 14 of the elastomeric closure 10 .
  • the barrier film 16 can be any barrier material suitable for its intended use, and preferably a barrier film material having a low water vapor and/or oxygen (i.e., fluids) transmission rate.
  • Suitable barrier materials can include, but are not limited to, a metallic foil, such as aluminum foil or stainless steel foil, a polyester film, a polyamide film, a polyvinylchloride film, halogenated polymer films, non-halogenated polyisobutylene-isoprene rubber films, polyvinylidene chloride (PVDC) films, cyclic olefin copolymer (COC) films, polypropylene films, polyethylene films, polytetrafluoroethylene (PTFE) films, polychlorotrifluoroethylene (PCTFE) films (such as Aclar® from Honeywell International Inc. of Morristown, N.J.), silicone oxide (SiOx) coated polymer films, and/or combinations thereof.
  • Additional barrier film materials can also include polyvinyl chloride (
  • the barrier film 16 is a barrier film having a very low water vapor transmission and/or oxygen transmission rate, such as an aluminum foil film.
  • Aluminum foil is an excellent barrier to water vapor transmission with reported water vapor transmission rates as low as 0.001 g/m 2 /day.
  • the barrier film 16 has a thickness of about 0.01 mm to 1.0 mm, but could be of some lesser or greater thickness in some applications.
  • the barrier film 16 can be directly bonded to the top and bottom portions 12 , 14 of the elastomeric closure 10 or alternatively bonded thereto with the use of additional bonding layers 102 , 102 ′.
  • the bonding layers 102 , 102 ′ are layered between the barrier film 16 and the opposing surfaces of the top portion 12 and the bottom portion 14 .
  • the bonding layers 102 , 102 ′ provide a means to enhance the bonding strength between the barrier film 16 and the top and bottom portions 12 , 14 of the elastomeric closure 10 .
  • the bonding layers 102 , 102 ′ can be an organic material layer or an inorganic material layer.
  • Preferred exemplary bonding layer materials include an epoxy, an adhesive primer, a silane compound or a resin/silicone based primer, e.g., Elastobond 11, Elastobond 24 and Elastobond 56 from Avokal GmbH of Wuppertal Germany, and HV Primer from Dow Corning of Midland, Mich., or a deposition layer formed from SiO 2 , Al 2 O 3 , or diamond-like carbon.
  • the elastomeric closure 10 can alternatively be configured to include an adhesion promoter, such as, a silane compound, an epoxy, a polymer resin, an adhesive and primers, e.g., silane based adhesives MEGUMTM from Chemetall, ROBONDTM from Dow Corning of Midland, Mich., and THIXONTM from Morton, and CHEMOSIL® from Chemlok and Henckel, for promoting bonding between the barrier film 16 and the top and bottom portions 12 , 14 of the elastomeric closure 10 .
  • the adhesion promoter is mixed and/or compounded with the uncured elastomeric resin used to mold the top and bottom portions 12 , 14 of the elastomeric closure 10 .
  • adhesion promoters within the uncured elastomer resin used to mold the elastomeric closure 10 advantageously allows for improved bonding between the barrier film 16 and the surfaces of the elastomeric closure 10 to which it is bonded to. Additional adhesion promoters applicable to the present invention are disclosed in U.S. Pat. Nos. 7,807,015 and 6,759,129, the disclosures of which are hereby incorporated by reference herein in its entirety.
  • the present method has been developed to form the elastomeric closure 10 , wherein the top portion 12 and the bottom portion 14 are directly bonded to the barrier film 16 .
  • the barrier film 16 is plasma treated on both its upper and lower surfaces to form a plasma activated barrier film surface.
  • the plasma treatment results in structural modifications to the surfaces of the barrier film 16 resulting in e.g., high surface energy and wetting of the barrier film's surfaces.
  • the plasma treated barrier film 16 can more effectively be bonded to the surfaces of the top and bottom portions 12 , 14 ( FIG. 8 ) of the elastomeric closure 10 by, e.g., hot pressing and vulcanizing.
  • plasma treatment methods for treating barrier films are known in the art and a detailed description of their structure, operation and function is not necessary for a complete understanding of the present invention.
  • exemplary plasma treatment methods include Openair® plasma by Plasmatreat of Elgin, Ill., CF 4 Plasma, and Interface or Oxygen Plasma.
  • the plasma treated barrier film 16 is layered on top of a first layer of uncured elastomer 14 ′ within a bottom mold 200 .
  • the barrier film 16 and first layer of uncured elastomer 14 ′ is then hot pressed and vulcanized to form the bottom portion 14 bonded to the barrier film 16 .
  • the time, heat and pressure for hot pressing the bottom portion 14 to the barrier film will depend upon the specific elastomeric material used to form the bottom portion 14 .
  • elastomeric materials and compression molding processes are known in the art and a detailed description of the compression molding processes' time, temperature and pressure specifications is not necessary for a complete understanding of the present invention.
  • An exemplary compression molding process applicable to the present invention is disclosed in U.S.
  • the hot pressing and vulcanizing is conducted preferably at temperatures of about 140 to 220 degrees Celsius and pressures of about 40 to 70 kg/cm 2 for about 2 to 15 minutes.
  • a second layer of uncured elastomer 12 ′ is assembled within a top mold 202 and the already formed bottom portion 14 with barrier film 16 is placed in another mold 204 after trimming.
  • the second layer of uncured elastomer 12 ′ is then hot pressed and vulcanized against the exposed surface of the barrier film 16 situated within the mold 204 , thus forming a unitary structure of a top portion 12 bonded to the barrier film 16 and the bottom portion 14 .
  • the hot pressing and vulcanizing is conducted preferably at temperatures of about 140 to 220 degrees Celsius and pressures of about 40 to 70 kg/cm 2 for about 2 to 15 minutes.
  • the present method has been developed to form the elastomeric closure 10 , wherein the top portion 12 and the bottom portion 14 are bonded to the barrier film 16 via bonding layer 102 , 102 ′.
  • the barrier film 16 is formed with the first bonding layer 102 on a bottom surface of the barrier film 16 and a second bonding layer 102 ′ formed a top surface of the barrier film 16 .
  • the bonding layers 102 , 102 ′ can be any suitable bonding agent/material that bonds the barrier film 16 to the top and bottom portions 12 , 14 and provides the necessary bonding strength.
  • the bonding layers 102 , 102 ′ are an epoxy, an adhesive primer, a silane or a silicone based primer, e.g., Elastobond 11, Elastobond 24 and Elastobond 56 from Abokol Heller and HV Primer from Dow Corning of Midland, Mich., or a deposition layer formed from SiO 2 , Al 2 O 3 , or an organic material, such as diamond-like carbon.
  • Such bonding layers 102 , 102 ′ can be applied to the barrier film 16 by e.g., dip coating, curtain coating, spray coating, chemical deposition, physical deposition and the like.
  • Such techniques for coating films with bonding layers are known in the art, as such, a detailed description of such processes is not necessary for a complete understanding of the present invention.
  • plasma enhanced chemical vapor deposition is a preferred method of coating the barrier film 16 with bonding layers 102 , 102 ′ formed as a deposition layer composed of SiO 2 , Al 2 O 3 , or an organic material, such as diamond-like carbon ( FIG. 11 ).
  • the barrier film 16 with bonding layers 102 , 102 ′ is then layered on top of a first layer of uncured elastomer 14 ′ within a bottom mold 200 .
  • the barrier film 16 and first layer of uncured elastomer 14 ′ is then hot pressed and vulcanized to form the bottom portion 14 bonded to the barrier film 16 .
  • the time, heat and pressure for hot pressing the bottom portion 14 to the barrier film 16 is similar to the method described above in the first aspect of the invention. However, the hot pressing and vulcanizing is conducted preferably at temperatures of about 140 to 220 degrees Celsius and pressures of about 40 to 70 kg/cm 2 for about 2 to 15 minutes.
  • a second layer of uncured elastomer 12 ′ is assembled within a top mold 202 and the already formed bottom portion 14 with barrier film 16 is placed in another mold 204 after trimming.
  • the second layer of uncured elastomer 12 ′ is then hot pressed and vulcanized against the exposed surface of the barrier film 16 situated within the mold 204 , thus forming a unitary structure of a top portion 12 bonded to the barrier film 16 and the bottom portion 14 .
  • the hot pressing and vulcanizing is conducted preferably at temperatures of about 140 to 220 degrees Celsius and pressures of about 40 to 70 kg/cm 2 for about 2 to 15 minutes.
  • the present method has been developed to form the elastomeric closure 10 , wherein the top portion 12 and the bottom portion 14 are bonded directly to the barrier film 16 .
  • a first step (Step 300 , see FIG. 14 ) the uncured elastomer used to from the elastomeric closure 10 is mixed/compounded with an adhesion promoter.
  • the adhesion promoter can be, e.g., a silane compound, an epoxy, a polymer resin or an adhesive.
  • the barrier film 16 is then layered on top of a first layer of uncured elastomer 14 ′ with adhesion promoter within a bottom mold 200 (Step 302 , see FIG. 9 ).
  • the barrier film 16 and first layer of uncured elastomer 14 ′ with adhesion promoter is then hot pressed and vulcanized to form the bottom portion 14 bonded to the barrier film 16 (Step 304 ).
  • the time, heat and pressure for hot pressing the bottom portion 14 to the barrier film 16 is similar to the method described above in the first aspect of the invention. However, the hot pressing and vulcanizing is conducted preferably at temperatures of about 140 to 220 degrees Celsius and pressures of about 40 to 70 kg/cm 2 for about 2 to 15 minutes.
  • a second layer of uncured elastomer 12 ′ with adhesion promoter is assembled within a top mold 202 , and the already formed bottom portion 14 with barrier film 16 is placed in another mold 204 after trimming.
  • the second layer of uncured elastomer 12 ′ with adhesion promoter is then hot pressed and vulcanized against the exposed surface of the barrier film 16 situated within the mold 204 , thus forming a unitary structure of a top portion 12 bonded to the barrier film 16 and the bottom portion 14 .
  • the hot pressing and vulcanizing is conducted preferably at temperatures of about 140 to 220 degrees Celsius and pressures of about 40 to 70 kg/cm 2 for about 2 to 15 minutes.
  • the elastomeric closure 10 advantageously provide for a barrier film 16 within the elastomeric closure 10 .
  • the elastomeric closure 10 with the internal barrier film 16 advantageously minimizes the total area where water vapor or gases can transmit or diffuse through the elastomeric closure 10 .
  • the present invention advantageously provides for an elastomeric closure 10 with a barrier film 16 that does not come in direct contact with the contents of a vessel, such as lyophilized drugs. That is, the present invention eliminates the barrier film material as an additional source of potential contaminants above and beyond that of the elastomeric material itself.
  • the elastomeric portions of the elastomeric closure 10 completely encapsulates the barrier film 16 , or is flush with the exposed surfaces of the barrier film 16 .
  • Such an internal barrier film 16 also provides for a seamless transition for users of the closures, as the elastomeric closure 10 with the internal barrier film 16 appears essentially the same as elastomeric closures without an internal barrier film 16 .
  • the barrier film 16 is not readily visible to a user.
  • a barrier film 16 and especially a barrier film 16 of a metallic barrier material, is not susceptible to problematic fragmentation or debris caused by needle penetration or needle coring, as the barrier film 16 would be completely or substantially completely surrounded by elastomer on both sides of the barrier film 16 .
  • such elastomeric closures 10 with a barrier film 16 provide the ability to increase the shelf life of moisture sensitive drugs, thereby providing added value to consumers and manufacturers.
  • the present methods of applying a barrier film 16 internally to an elastomeric component can also be applied to numerous other elastomeric devices as well.
  • the barrier film can be applied to any device having an elastomeric component that requires high barrier properties against water vapor transmission and/or gas (such as oxygen) transmission.
  • Such components can include plunger tips 400 having a barrier film 416 for syringes, tip caps 500 having a barrier film 516 for syringes and sealing disks 600 having a barrier film 616 , as shown in FIGS. 15 and 16 .
  • the foregoing methods of manufacturing the elastomeric closure 10 with barrier layer also provide the necessary bonding strength between the barrier film 16 and the elastomeric material of the elastomeric closure 10 .
  • the inventor has also surprisingly found that the foregoing methods result in elastomeric closures having varying bonding strengths between the barrier film 16 and the top and bottom portions 12 , 14 , depending upon the specific method of achieving bonding e.g., bonding layers, plasma treating the barrier film, and adhesion promoters, and the particular materials used for the elastomeric closure 10 and the barrier film 16 .
  • bonding layers are preferred when forming bromobutyl elastomeric closures with aluminum foil or a polyester/Al 2 O 3 film, while the use of a plasma treated barrier film is preferred with a silicone elastomeric closure and a polyester/Al 2 O 3 film.
  • Uncured bromobutyl rubber was used as the starting material for molding the top and bottom portions of a bromobutyl elastomeric closure.
  • the uncured bromobutyl rubber was placed within a bottom mold cavity and then a layer of aluminum foil coated with epoxy was placed on top of the uncured bromobutyl rubber.
  • the uncured bromobutyl rubber and aluminum foil was then hot pressed at 180 degrees C. for 4 minutes.
  • the vulcanized bottom portion and aluminum foil was then removed, trimmed and placed in another bottom mold cavity.
  • a second layer of uncured bromobutyl rubber was then placed in a top mold cavity in facing engagement with the exposed surface of the aluminum foil.
  • the second layer of uncured bromobutyl rubber was then hot pressed to the vulcanized bottom portion and aluminum foil to form a unitary structure defining the bromobutyl elastomeric closure, at 180 degrees C. for 6 minutes.
  • Uncured bromobutyl rubber was used as the starting material for molding the top and bottom portions of a bromobutyl elastomeric closure.
  • the uncured bromobutyl rubber was placed within a bottom mold cavity and then a barrier film of polyester/Al 2 O 3 coated with a silane compound was placed on top of the uncured bromobutyl rubber.
  • the uncured bromobutyl rubber and polyester/Al 2 O 3 film was then hot pressed at 180 degrees C. for 4 minutes. The vulcanized bottom portion and polyester/Al 2 O 3 film was then removed, trimmed and placed in another bottom mold cavity.
  • a second layer of uncured bromobutyl rubber was then placed in a top mold cavity in facing engagement with the exposed surface of the polyester/Al 2 O 3 film.
  • the second layer of uncured bromobutyl rubber was then hot pressed to the vulcanized bottom portion and polyester/Al 2 O 3 film to form a unitary structure defining the bromobutyl elastomeric closure, at 180 degrees C. for 6 minutes.
  • Uncured silicone rubber was used as the starting material for molding the top and bottom portions of a silicone elastomeric closure.
  • the uncured silicone rubber was placed within a bottom mold cavity and then a barrier film layer of polyester/Al 2 O 3 coated with a silane compound was placed on top of the uncured silicone rubber.
  • the uncured silicone rubber and polyester/Al 2 O 3 film was then hot pressed at 140 degrees C. for 4 minutes.
  • the vulcanized bottom portion and polyester/Al 2 O 3 film was then removed, trimmed and placed in another bottom mold cavity.
  • a second layer of uncured silicone rubber was then placed in a top mold cavity in facing engagement with the exposed surface of the polyester/Al 2 O 3 film.
  • the second layer of uncured silicone rubber was then hot pressed to the vulcanized bottom portion and polyester/Al 2 O 3 film to form a unitary structure defining the silicone elastomeric closure, at 140 degrees C. for 6 minutes.
  • Uncured silicone rubber was used as the starting material for molding the top and bottom portions of a silicone elastomeric closure.
  • the barrier film used was a polyester/Al 2 O 3 film that had been plasma treated on both sides.
  • the uncured silicone rubber was placed within a bottom mold cavity and then the polyester/Al 2 O 3 barrier film was placed on top of the uncured silicone rubber.
  • the uncured silicone rubber and polyester/Al 2 O 3 film was then hot pressed at 140 degrees C. for 4 minutes.
  • the vulcanized bottom portion and polyester/Al 2 O 3 film was then removed, trimmed and placed in another bottom mold cavity.
  • a second layer of uncured silicone rubber was then placed in a top mold cavity in facing engagement with the exposed surface of the polyester/Al 2 O 3 film.
  • the second layer of uncured silicone rubber was then hot pressed to the vulcanized bottom portion and polyester/Al 2 O 3 film to form a unitary structure defining the silicon elastomeric closure, at 140 degrees C. for 6 minutes.

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  • Infusion, Injection, And Reservoir Apparatuses (AREA)
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US10099821B2 (en) * 2014-09-16 2018-10-16 Sumitomo Rubber Industries, Ltd. Method for manufacturing a medical rubber closure
US11406565B2 (en) 2015-03-10 2022-08-09 Regeneran Pharmaceuticals, Inc. Aseptic piercing system and method
US11547801B2 (en) 2017-05-05 2023-01-10 Regeneron Pharmaceuticals, Inc. Auto-injector
USD1007676S1 (en) 2021-11-16 2023-12-12 Regeneron Pharmaceuticals, Inc. Wearable autoinjector

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US9878101B2 (en) 2010-11-12 2018-01-30 Sio2 Medical Products, Inc. Cyclic olefin polymer vessels and vessel coating methods
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EP2846755A1 (de) 2012-05-09 2015-03-18 SiO2 Medical Products, Inc. Saccharidschutzschicht für eine arzneimittelverpackung
WO2014071061A1 (en) 2012-11-01 2014-05-08 Sio2 Medical Products, Inc. Coating inspection method
US9903782B2 (en) 2012-11-16 2018-02-27 Sio2 Medical Products, Inc. Method and apparatus for detecting rapid barrier coating integrity characteristics
US9764093B2 (en) 2012-11-30 2017-09-19 Sio2 Medical Products, Inc. Controlling the uniformity of PECVD deposition
AU2013352436B2 (en) 2012-11-30 2018-10-25 Sio2 Medical Products, Inc. Controlling the uniformity of PECVD deposition on medical syringes, cartridges, and the like
EP2961858B1 (de) 2013-03-01 2022-09-07 Si02 Medical Products, Inc. Beschichtete spritze.
US9937099B2 (en) 2013-03-11 2018-04-10 Sio2 Medical Products, Inc. Trilayer coated pharmaceutical packaging with low oxygen transmission rate
US20160015600A1 (en) 2013-03-11 2016-01-21 Sio2 Medical Products, Inc. Coated packaging
WO2014144926A1 (en) 2013-03-15 2014-09-18 Sio2 Medical Products, Inc. Coating method
CN203173078U (zh) * 2013-04-23 2013-09-04 徐正敏 一种吸氧型保质瓶盖
ITPD20130277A1 (it) * 2013-10-08 2015-04-09 Microcell Srl Tappo perfezionato per contenitori
EP3693493A1 (de) 2014-03-28 2020-08-12 SiO2 Medical Products, Inc. Antistatische beschichtungen für kunststoffbehälter
FR3029468B1 (fr) * 2014-12-09 2018-04-27 Inergy Automotive Systems Research (Societe Anonyme) Systeme pour vehicule automobile
US11077233B2 (en) 2015-08-18 2021-08-03 Sio2 Medical Products, Inc. Pharmaceutical and other packaging with low oxygen transmission rate
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US10099821B2 (en) * 2014-09-16 2018-10-16 Sumitomo Rubber Industries, Ltd. Method for manufacturing a medical rubber closure
US11406565B2 (en) 2015-03-10 2022-08-09 Regeneran Pharmaceuticals, Inc. Aseptic piercing system and method
US11547801B2 (en) 2017-05-05 2023-01-10 Regeneron Pharmaceuticals, Inc. Auto-injector
USD1007676S1 (en) 2021-11-16 2023-12-12 Regeneron Pharmaceuticals, Inc. Wearable autoinjector

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CN102725202A (zh) 2012-10-10
US20120205374A1 (en) 2012-08-16
WO2011044569A1 (en) 2011-04-14
CN102725202B (zh) 2015-03-25
EP2485957A1 (de) 2012-08-15
EP2485957B1 (de) 2013-12-11

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